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Suzuki LT250R 1988-1992 Service Repair Manual

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The Suzuki LT250R, produced from 1988 to 1992, represents the second generation of this high-performance sport ATV. Engineered for aggressive off-road riding and competitive use, it is renowned for its...
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Suzuki LT250R 1988-1992 Service Repair Manual
The Suzuki LT250R, produced from 1988 to 1992, represents the second generation of this high-performance sport ATV. Engineered for aggressive off-road riding and competitive use, it is renowned for its agile handling, stable chassis, and the strong mid-range and top-end power delivered by its 249cc, 2-stroke, liquid-cooled engine. This model builds upon Suzuki's heritage of creating lightweight, potent machines, offering enthusiasts and racers a capable platform for demanding terrain and dynamic performance. This comprehensive service repair manual provides detailed guidance for maintaining and repairing the Suzuki LT250R across its covered model years. It offers complete coverage of essential systems, including engine maintenance, transmission service, suspension and braking system overhauls, and electrical system diagnostics. The manual includes a troubleshooting guide, wiring diagrams, torque specifications, and descriptions of special tools, empowering owners and technicians with the knowledge needed for effective upkeep and repair.
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
LT250R
Generation:
2nd Generation (RG)
Model Years Covered:
1988, 1989, 1990, 1991, 1992
Product Name:
Suzuki LT250R 1988-1992 Service Repair Manual PDF Download
👋 Introduction
Market Position
Segment:
High-performance sport ATV
Target Audience:
Enthusiasts, racers, and DIY mechanics seeking detailed repair information
Competitive Analysis
Key Competitors:
Yamaha Warrior 350, Honda TRX250R (previous generation), Kawasaki Tecate-4
Key Features
Performance Focus:
Engineered for aggressive off-road riding and competitive use
Handling Capabilities:
Renowned for its agile handling and stable chassis
Power Delivery:
Strong mid-range and top-end power from its 2-stroke engine
📋 Manual Details
Coverage Areas
Engine Maintenance:
Complete
Transmission Service:
Complete
Suspension System Repair:
Complete
Braking System Overhaul:
Complete
Electrical System Diagnostics:
Complete
Chassis And Bodywork Repair:
Complete
Troubleshooting Guide:
Comprehensive
Wiring Diagrams:
Included
Torque Specifications:
All
Special Tools:
Listed and described
Page Count
Estimated Pages:
300+
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
249cc, 2-stroke, liquid-cooled, reed valve, single-cylinder
Carburetion:
Mikuni VM32SS
Ignition:
CDI
Transmission:
6-speed manual
Clutch:
Wet multi-plate
Cooling System:
Liquid cooling, radiator, fan
Fuel System:
Pre-mix (100:1 or 50:1 ratio depending on application)
Suspension Front:
Independent double A-arm with adjustable shock absorbers (Showa or similar)
Suspension Rear:
Swingarm with single adjustable shock absorber (Pro-Link system)
Brakes Front:
Dual hydraulic disc brakes
Brakes Rear:
Single hydraulic disc brake
Electrical System:
12V DC system, lighting, battery charging
Procedures Included
Engine Rebuild:
Complete disassembly, inspection, and reassembly
Carburetor Tuning:
Adjustment, cleaning, and rebuilding
Suspension Setup:
Preload, compression, and rebound adjustments
Brake Bleeding:
Hydraulic system maintenance
Electrical Troubleshooting:
Fault finding for ignition, lighting, and charging circuits
Chain Adjustment:
Proper tensioning and lubrication
Wheel Bearing Service:
Replacement and lubrication
Cooling System Maintenance:
Flushing, coolant replacement, thermostat service
Spark Plug Replacement:
Selection and gapping
Air Filter Cleaning:
Service and replacement
Technical Depth
Depth:
Comprehensive: From basic maintenance and fluid changes to complete engine and transmission overhauls, including detailed diagnostics and troubleshooting for all major systems.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text
Printability:
Printable
Print Quality
Image Resolution:
High resolution for clear diagrams and text
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, liquid-cooled, single-cylinder
Displacement:
249 cc (15.2 cu. in.)
Bore X Stroke:
72.0 mm x 61.0 mm (2.83 in. x 2.40 in.)
Compression Ratio:
7.0:1
Valvetrain:
Reed valve induction
Performance
Horsepower Est:
Approximately 30-35 HP (varies by specific model year and tuning)
Torque Est:
Approximately 20-24 lb-ft (varies)
Fuel System
Carburetor Model:
Mikuni VM32SS
Fuel Type:
Unleaded gasoline with 2-stroke oil pre-mix
Recommended Oil Mix:
50:1 or 100:1 (refer to manual for specific recommendations and conditions)
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Clutch Type:
Wet multi-plate
Final Drive:
Chain drive
Features
Gear Ratios:
Detailed in manual
📐 Dimensions
Exterior
Length:
Approx. 1970 mm (77.6 in.)
Width:
Approx. 1170 mm (46.1 in.)
Height:
Approx. 1120 mm (44.1 in.)
Wheelbase:
Approx. 1270 mm (50.0 in.)
Ground Clearance:
Approx. 250 mm (9.8 in.)
Weights
Dry Weight:
Approx. 183 kg (403 lbs.)
Fuel Capacity:
Approx. 13.0 L (3.4 US gal)
🛡️ Safety Features
Ratings
Safety Standard:
ATV safety standards of the era
Active Features
Braking System:
Powerful hydraulic disc brakes front and rear
Suspension:
Long-travel, adjustable suspension for stability and control
Passive Features
Chassis Design:
Tuned for rider control and stability
Tire Design:
Aggressive tread pattern for off-road traction
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic sport ATV design)
Driver Assistance
Assistance Features:
N/A (Rider-controlled operation)
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Engine:
Refer to manual for specific break-in and regular service intervals
Air Filter Cleaning:
After every few rides, depending on conditions
Chain Lubrication:
Regularly, especially after riding in wet conditions
Spark Plug Inspection:
Periodically, check for fouling and proper gap
Brake Fluid Flush:
Annually or as needed based on condition
Coolant Flush:
Every 1-2 years
Fluid Specifications
Engine Oil:
2-stroke oil mixed with gasoline (refer to manual for specific type and ratio)
Coolant:
Ethylene glycol based antifreeze (50/50 mix with distilled water recommended)
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid
Transmission Fluid:
SAE 10W-30 API SE or SF (refer to manual for specific type and capacity)
Grease:
Lithium-based multi-purpose grease
Known Issues
Common Problems:
Carburetor jetting sensitivity, clutch wear, occasional electrical connector issues, worn suspension bushings.
Preventative Measures:
Regular cleaning of carburetor and air filter, proper oil mixing, consistent lubrication of moving parts, and periodic inspection of electrical connections.
📚 Vehicle History
Brand Heritage
Heritage Focus:
Suzuki's reputation for lightweight, powerful 2-stroke engines in performance vehicles
Model Evolution
Generation Development:
The second generation LT250R (RG series) saw significant updates over its predecessor, refining performance and handling.
Key Upgrades:
Liquid cooling, improved suspension, revised styling, and enhanced power delivery.
Production
Production Period:
1985-1992 (with major redesigns in 1987 and 1988)
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Awards:
Recognized for its performance and handling in its class during its production run.
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